Manufacturability of Ti-Al-4V Hollow-Walled Lattice Struts by Laser Powder Bed Fusion

Hollow-walled lattices are novel cellular materials with lower densities than conventional dense-walled lattices. However, their manufacturability by laser powder bed fusion (LPBF) is not yet established. This study investigates the LPBF of Ti-6Al-4V hollow-walled struts respect to strut outer diameter, wall thickness (controlled scan path), and inclination angle, while length purposely limited 10–15 mm, typical lattice unit dimensions. The was reliable for diameters exceeding 0.5 mm thicknesses 0.24 over inclines 22.5°–90°. To ensure a manufacturable hollow cylindrical channel LPBF, we recommend minimum inner diameter 4Dv(90) according feedstock size distribution. average inconsistency 5.13% between designed manufactured substantially that achievable manufacturing. findings this provide necessary guidance future manufacture LPBF.